Fluid filtration system

ABSTRACT

A method of filtering a fluid, including flowing a fluid from a first side of a filter member to a second side of the filter member, the fluid containing dissolved impurities. In addition, the method includes inducing fluid cavitation within the fluid to precipitate out at least a portion of the dissolved impurities. Further, the method includes controlling a pressure differential across the filter member. Still further, the method includes, maintaining or further inducing the fluid cavitation within the fluid in response to controlling the pressure differential. Related systems are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a divisional of U.S. patent application Ser.No. 13/958,305, filed on Aug. 2, 2013, entitled “Fluid FiltrationSystem,” and claiming priority to U.S. Provisional Patent ApplicationNo. 61/683,712, filed on Aug. 15, 2012, both of which are herebyincorporated herein by reference.

BACKGROUND

The present disclosure relates to filtration or filtering systems forfluids. More particularly, the disclosure relates to a filtering systemto remove particulate matter from a fluid. The filtering system isconfigured to remove solid particles from the fluids such that thefluids can then be recycled.

In modern industrial practice, it is common to filter fluids (e.g.,liquids) in order to prepare such fluids for use, reuse, and/orintroduction into the natural environment. For example, water used andproduced in oil and gas well fracturing (or stimulation) operationsrequires treatment or processing before re-use and disposal. The wateris treated to remove chemicals that were added to the water before useand/or chemicals and sediment suspended in the water after use as aby-product of the well stimulation. The water, commonly referred to asused flowback fracturing (“frac”) water and produced water, may havebeen processed to ensure that it is capable of being used initially forstimulating oil and gas wells and is again processed for that purpose.Without appropriate treatment, contaminants or other suspendedparticulate matter entering the frac water can cause formation damage,plugging, lost production, and increased demand for chemical treatmentadditives. In addition, the water is processed for disposal, forexample, to prevent contamination of ground water resources.

Because the filtered fluids and the suspended contaminants andparticulates can vary widely depending on the specific application, itis advantageous for a filtering system (or systems) to be configured toreceive and filter various fluids, and to be adaptable or adjustable tofilter such fluids using a single system.

SUMMARY

In some embodiments, a method of filtering a fluid includes flowing afluid from a first side of a filter member to a second side of thefilter member, the fluid containing dissolved impurities. In addition,the method includes inducing fluid cavitation within the fluid toprecipitate out at least a portion of the dissolved impurities. Further,the method includes controlling a pressure differential across thefilter member. Still further, the method includes maintaining or furtherinducing the fluid cavitation within the fluid in response tocontrolling the pressure differential.

In some embodiments, a system for filtering a fluid includes a filterassembly further including a vessel defining a pressure chamber. Inaddition, the filter assembly includes a filter screen disposed withinthe vessel, the screen dividing the pressure chamber into a firstsubchamber and a second subchamber. Further, the filter assemblyincludes a first pressure sensor configured to sense a pressure withinthe first subchamber and generate a first pressure signal. Stillfurther, the filter assembly includes a second pressure sensorconfigured to sense a pressure within the second subchamber andconfigured to generate a second pressure signal. In addition, the systemincludes a first pump fluidly coupled to the filter assembly, the firstpump having a discharge pressure. Further, the system includes acontroller electrically coupled to the first sensor, the second sensor,and the first pump, wherein the controller is configured to adjust thedischarge pressure of the first pump based on the first pressure signaland the second pressure signal to induce or maintain cavitation withinthe fluid as the fluid flows from the first subchamber to the secondsubchamber.

In some embodiments, a method of filtering a fluid includes flowing afluid into a filter assembly, wherein the filter assembly comprises avessel defining a pressure chamber. In addition, the filter assemblyincludes a filter screen disposed within the vessel, the screen dividingthe pressure chamber into a first subchamber and a second subchamber. Inaddition, the method comprises flowing the fluid from the firstsubchamber to the second subchamber. Further, the method comprisescontrolling a first pressure of the first subchamber relative to asecond pressure of the second subchamber to induce cavitation in theflowing fluid. Still further, the method comprises precipitating outdissolved impurities within the fluid during the cavitation.

Embodiments described herein comprise a combination of features andadvantages intended to address various shortcomings associated withcertain prior devices, systems, and methods. The foregoing has outlinedrather broadly the features and technical advantages of the invention inorder that the detailed description of the invention that follows may bebetter understood. The various characteristics described above, as wellas other features, will be readily apparent to those skilled in the artupon reading the following detailed description, and by referring to theaccompanying drawings. It should be appreciated by those skilled in theart that the conception and the specific embodiments disclosed may bereadily utilized as a basis for modifying or designing other structuresfor carrying out the same purposes of the invention. It should also berealized by those skilled in the art that such equivalent constructionsdo not depart from the spirit and scope of the invention as set forth inthe appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed description of exemplary embodiments of the disclosure,reference will now be made to the accompanying drawings in which:

FIG. 1 is a schematic, partial cross-sectional view of an embodiment ofa filter system in accordance with the principles disclosed herein;

FIG. 2 is a schematic, partial cross-sectional view of an embodiment ofthe filter assembly of the filter system of FIG. 1;

FIG. 3 is a side view of an alternative embodiment of the filterassembly of the filter system of FIG. 1;

FIG. 4 is an enlarged schematic, cross-sectional view of the filterscreen of the filter assembly of FIG. 2 taken along portion III-III;

FIG. 5 is an enlarge schematic cross-sectional view of an alternativeembodiment of the filter screen of the filter assembly of FIG. 2;

FIG. 6 is a perspective view of one of the media vortex generator cupsof the filter assembly of FIG. 2;

FIG. 7 is a schematic, partial cross-sectional view of an alternativeembodiment of the filter assembly of the filter system of FIG. 1;

FIG. 8 is a schematic, partial cross-sectional view of the filter systemof FIG. 1 operating in an internal clean effect mode of operation;

FIG. 9 is a schematic, partial cross-sectional view of the filter systemof FIG. 1 operating in a separation clean effect mode of operation;

FIG. 10 is a schematic, partial cross-sectional view of the filtersystem of FIG. 1 operating in a reject state;

FIG. 11 is an enlarged schematic, cross-sectional view of the filterscreen of the filter assembly of FIG. 4 with micro-holes formed on theradially inner surface thereof;

FIG. 12 is a schematic, partial cross-sectional view of anotherembodiment of a filter system in accordance with the principlesdisclosed herein;

FIG. 13 is a schematic, partial cross-sectional view of the filtersystem of FIG. 11 operating in a reject state;

FIG. 14 shows a block diagram of an embodiment of a method of filteringfluids in accordance with the principles disclosed herein; and

FIG. 15 shows a block diagram of another embodiment of a method offiltering fluids in accordance with the principles disclosed herein.

NOTATION AND NOMENCLATURE

Certain terms are used throughout the following description and claimsto refer to particular system components. This document does not intendto distinguish between components that differ in name but not function.In the following discussion and in the claims, the terms “including” and“comprising” are used in an open-ended fashion, and thus should beinterpreted to mean “including, but not limited to . . . .” Also, theterm “couple” or “couples” is intended to mean either an indirect ordirect mechanical connection, or an indirect, direct, optical orwireless electrical connection. Thus, if a first device couples to asecond device, that connection may be through a direct mechanical orelectrical connection, through an indirect mechanical or electricalconnection via other devices and connections, through an opticalelectrical connection, or through a wireless electrical connection. Inaddition, as used herein the terms “axial” and “axially” generally meanalong or parallel to a central axis (e.g., central axis of a body orport), while the terms “radial” and “radially” generally meanperpendicular to the central axis. For instance, an axial distancerefers to a distance measured along or parallel to the central axis, anda radial distance means a distance measured perpendicular to the centralaxis. Further, the term “software” includes any executable code capableof running on a processor, regardless of the media used to store thesoftware. Thus, code stored in memory (e.g., non-volatile memory), andsometimes referred to as “embedded firmware,” is included within thedefinition of software. The recitation “based on” is intended to mean“based at least in part on.” Therefore, if X is based on Y, X may bebased on Y and any number of other factors.

In the following description and figures, embodiments of a filter systemare described for filtering both suspended and dissolved impurities fromflowback frac water. However, it should be appreciated that embodimentsof the filter system described herein and methods relating thereto maybe utilized in a wide variety of systems and applications which employsuch systems to filter suspended and dissolved solids from a liquid(e.g., water). For example, embodiments of the filtering systemdescribed herein may be used to filter both suspended and dissolvedparticulates (e.g., sodium chloride) from sea water. Therefore,filtering of flowback frac water is merely one of many potential uses ofthe filtering system and methods described herein. Thus, any referenceto flowback frac water (or any other fluid) and related subject matteris merely included to provide context to the description containedherein and is in no way meant to limit the scope thereof. At varioustimes, the word “filter” may also be interchanged with words such as“filtering” or “filtration,” though no difference in meaning is intendedunless otherwise noted.

DETAILED DESCRIPTION

The following discussion is directed to various embodiments of thedisclosure. Although one or more of these embodiments may be preferred,the embodiments disclosed should not be interpreted, or otherwise used,as limiting the scope of the disclosure, including the claims. Inaddition, one skilled in the art will understand that the followingdescription has broad application, and the discussion of any embodimentis meant only to be exemplary of that embodiment, and not intended tointimate that the scope of the disclosure, including the claims, islimited to that embodiment.

Referring to FIG. 1, an embodiment of a filter system 10 is shown. Thefilter system 10 generally comprises a filter assembly 20, a start ordirty tank 40, a finish or clean tank 60, a first or feed pump 50, asecond or reversing pump 70, and a control system 80.

Each of the components (e.g., tanks 40, 60, assembly 20, pumps 50, 70)of system 10 are fluidly coupled together through a plurality ofconduits 12, 14, 16, 17, 18, 19. In particular, system 10 includes afeed line 12, a flush line 14, a discharge line 16, a return line 18, arecirculation line 17, and a pair of injection lines 19. Each of thelines 12, 14, 16, 17, 18, 19 comprises any suitable conduit capable ofchanneling fluids therethrough. For example, lines 12, 14, 16, 17, 18,19 may comprise pipes, hoses, open water channels, or other fluidconveyances, while still complying with the principles disclosed herein.

Further, system 10 also includes a plurality of valves disposed atvarious locations along lines 12, 14, 16, 17, 18, 19 to control the flowof fluids through system 10 during operation. In particular, a checkvalve 42 is disposed along feed line 12 and is configured to restrictfluid flow from assembly 20 toward feed pump 50. An actuatable valve 47is also disposed along feed line 12 to selectively control fluidcommunication between tank 40 and assembly 20 along line 12. Inaddition, a check valve 41 is disposed along flush line 14 and isconfigured to restrict fluid flow from tank 40 toward assembly 20 alongline 14. An actuatable valve 44 is also disposed along flush line 14 toselectively control fluid flow between assembly 20 and tank 40 alongline 14. Further, a check valve 49 is disposed along discharge line 16and is configured to restrict fluid flow from tank 60 toward assembly20. An actuatable valve 43 is also disposed along the discharge line 16to selectively control fluid communication between assembly 20 and tank60 along line 16. Still further, a check valve 46 is disposed alongreturn line 18 and is configured to restrict fluid flow from injectionlines 19 toward reversing pump 70. An actuatable valve 43 is alsodisposed along line 18 to selectively control fluid flow between pump 70and assembly 20 along lines 18, 19. Still further, an actuatable valve48 is disposed along recirculation line 17 to selectively control fluidflow between pump 70 and tank 60 along line 17.

Each of the check valves 41, 42, 46, 49 may be any suitable valve whichallows fluid flow in only one direction. For example, in someembodiments, check valves 41, 42, 46, 49 may comprise a swing checkvalve, spring check valve, inline check valve, ball cone check valve, orsome combination thereof while still complying with the principlesdisclosed herein. In addition, valves 41, 42, 46, 49 may comprise anysuitable material and, in some embodiments, preferably comprise acorrosion resistant material. For example in some embodiments, valves41, 42, 46, 49 comprise stainless steel or brass. Also, the valves 43,44, 45, 47, 48 may be any suitable valve for controlling the flow offluids along a conduit. For example, in some embodiments, the valves 43,44, 45, 47, and 48 may comprise electro-magnetic valves,electro-hydraulic valves, electro-mechanical valves, or some combinationthereof. Further, in some embodiments, each of the valves 43, 44, 45,47, and 48 may comprise a pinch valve, ball valve, gate valve, knifevalve, pneumatic valve, hydraulic valve, electronic solenoid valve, orsome combination thereof. Still further, in some embodiments, valves 43,44, 45, 47, and 48 may comprise any suitable material and, in someembodiments, preferably comprise a corrosion resistant material. Forexample, in some embodiments, valves 43, 44, 45, 47, and 48 comprisestainless steel or brass.

Referring now to FIG. 2, in this embodiment, the filter assembly 20includes a pressure housing or vessel 22, and a filter member or screen38. Vessel 22 generally includes an elongate tubular body 24, having acentral, longitudinal axis 25, a first or upper end 24 a, a second orlower end 24 b opposite the upper end 24 a, a radially inner surface 24c extending axially between the ends 24 a, 24 b, and a radially outersurface 24 d extending axially between the ends 24 a, 24 b. In thisembodiment, a main clean water outlet 27 is axially disposed between theends 24 a, 24 b and extends radially between the surfaces 24 c, 24 d,while a pair of return inlets 29 are axially disposed between the cleanwater outlet 27 and the lower end 24 b and each also extends radiallybetween the surfaces 24 c, 24 d. clean water outlet 27 is coupled todischarge line 16, while return inlets 29 are each coupled to one of theinjection lines 19, previously described. It should be appreciated thatin other embodiments the specific locations of the inlets 27 and outlets29 may be altered and varied while still complying with the principlesdisclosed herein.

In this embodiment, vessel 22 also includes a first or upperintermediate cap 32A axially disposed at upper end 24 a of body 24 and asecond or lower intermediate cap 32B axially disposed at lower end 24 b.Each intermediate cap 32A, 32B is generally configured the same andincludes a first or coupling portion 34 and a second or funnel portion36. Coupling portion 34 is generally cylindrical in shape and isconfigured to engage with body 24 during construction of assembly 20.Funnel portion 36 of each intermediate cap 32A, 32B generally extendsaxially from the coupling portion 34 and includes an outer frustoconicalsurface 36 a and a throughbore 36 b. Further, vessel 22 includes a firstor upper cap 26 including a sealing surface 26 a and a throughbore 26 b,and a second or lower cap 28 including a sealing surface 28 a andthroughbore 28 b.

It should be appreciated that in some embodiments, intermediate caps32A, 32B are removed from vessel 22 while still complying with theprinciples disclosed herein. For example, referring briefly to FIG. 3,wherein an alternative embodiment of filter assembly 20 (designated asassembly 20′) is shown. Filter assembly 20′ includes many similarcomponents relative to the filter assembly 20. As a result, likereference numerals are used for like components and features, and sharedcomponents may not be called out or discussed in detail with referenceto FIG. 3, but the same description with regard to FIG. 2 appliesequally to the assembly 20′ of FIG. 3 unless otherwise noted. Instead,the focus of the discussion will be on variations or differences in thefilter assembly 20′ over the filter system 20. For example, in assembly20′, intermediate caps 32A, 32B are not disposed between caps 26, 28 andbody 24 of vessel 22 and caps 26, 28 each directly couple to body 24through a pair of mating flanges 75. In addition, the embodiment ofassembly 20′ shown in FIG. 3 also includes a mounting plate 73 whichfurther includes a plurality of mounting apertures or holes 72. Duringoperation, plate 73 is used to fix or mount assembly 20′ to a surface orparticular position by aligning holes 72 with corresponding holes on amounting surface (not shown) and then engaging a securing member (e.g.,screw, nail, bolt, rivet) through each of the holes 72 (and the alignedholes on the mounting surface). However, it should be appreciated thatin some embodiments, any other suitable mounting device or assembly(other than plate 73) may be used while still complying with theprinciples disclosed herein. Additionally, in some embodiments, nomounting assembly or device is included.

Referring back now to FIG. 2, during assembly of filter assembly 20,intermediate caps 32A, 32B are axially disposed between caps 26, 28 suchthat coupling portion 34 of intermediate cap 32A is axially disposedbetween sealing surface 26 a of cap 26 and upper end 24 of body, andcoupling section 34 of cap 28 is axially disposed between sealingsurface 28 a of cap 28 and lower end 24 b of body 24. Body 24,intermediate caps 32A, 32B, and caps 26, 28 may be secured to oneanother through any suitable method while still complying with theprinciples disclosed herein. For example, in some embodiments body 24,intermediate caps 32A, 32B, and caps 26, 28 may be secured to oneanother with bolts, rivets, welding, sintering, or some combinationthereof.

When the caps 26, 28 and intermediate caps 32A, 32B are coupled to theends 24 a, 24 b of body 24, respectively, a sealed inner pressurechamber 23 is formed that is defined by the surface 24 c andintermediate caps 32A, 32B. As will be described in more detail below,chamber 23 receives fluid (e.g., used flowback frac water, salt water)from dirty tank 40 during operations in order to facilitate cleaning andfiltering thereof. In some embodiments, chamber 23 may have a maximumallowable pressure of 450 psi, and an operating pressure of less than100 psi; however, it should be appreciated that in other embodiments,the maximum allowable and operating pressures may vary. In addition,during construction of assembly 20, the throughbore 36 b of upperintermediate cap 32A and the throughbore 26 b of upper cap 26 are eachcoaxially aligned along axis 25 to form a main dirty water inlet 11 intochamber 23. The throughbore 38 b of lower intermediate cap 32B and thethroughbore 28 b of lower cap 28 are also coaxially aligned along axis25 to form a flush fluid outlet 13 from chamber 23. In this embodiment,inlet 11 is coupled to feed line 12, while flush fluid outlet 13 iscoupled to flush line 14. Further, in some embodiments, many features ofa filter assembly 20 (e.g., vessel 22, caps 26, 28, and intermediatecaps 32A, 32B) comprise stainless steel; however, in other embodiments,the features of assembly 20 may comprise various other materials suchas, for example, carbon fiber, or steel alloys.

Referring now to FIGS. 2 and 4, a tubular filter member or screen 38 isdisposed within chamber 23 and is coaxially aligned with the axis 25. Inthis embodiment, screen 38 is a substantially cylindrical tube thatincludes a first or upper end 38 a, a second or lower 38 b opposite theupper end 38 a, a radially inner surface 38 c extending between the ends38 a, 38 b, and a radially outer surface 38 d also extending between theends 38 a, 38 b. As is best shown in FIG. 4, a plurality of apertures orholes 39 extend generally radially between the surfaces 38 c, 38 d andare disposed axially between the ends 38 a, 38 b. Holes 39 may be formedof any shape or cross-section while still complying with the principlesdisclosed herein. For example, in some embodiments, holes 39 may becircular, elliptical, polygonal, triangular, or diamond shaped. Further,regardless of the shape of holes 39, each hole 39 has a maximum diameteror clearance D₃₉, which thus defines the maximum particle size whichhole 39 will allow to pass therethrough. In some embodiments, diameterD₃₉ may range from 1 to 100 μm depending on the type of fluids to befiltered by assembly 20 while still complying with the principlesdisclosed herein. In some embodiments, screen 38 comprises a sinteredwire mesh or a sintered “Dutch Twill” and may further include a latticestructure to withstand operating pressures within chamber 23. Also, insome embodiments, screen 38 comprises stainless steel, although anysuitable material may be used, such as, for example, carbon fiber, aceramic, a synthetic material, or some combination thereof.

Reference is now made to FIG. 5, wherein an alternative embodiment ofscreen 38′ is shown. As with screen 38, previously described, screen 38′is a substantially cylindrical tube that includes a radially innersurface 38′c and a radially outer surface 38′d. In addition, screen 38′comprises multiple radially stacked layers that are sintered orotherwise engaged to one another. For example, in this embodiment,screen 38′ comprises a first or inner layer 38′A and a second or outerlayer 38′B; however, it should be appreciated that in other embodiments,more than two layers (e.g., layers 38′A, 38′B) may be included. In thisembodiment, inner layer 38′A includes a plurality of apertures or holes39′A extending radially from the surface 38′c to the outer layer 38′B,while the outer layer 38′B includes a plurality of apertures or holes39′B extending radially from the inner layer 38′A to the radially outersurface 38′d. As previously described for holes 39 of screen 38, eachhole 39′A, 39′B may comprise any shape while still complying with theprinciples disclosed herein. For example, in some embodiments, holes39′A, 39′B may be circular, elliptical, polygonal, triangular, ordiamond shaped. Further, each hole 39′A has a maximum diameter orclearance D_(39′A) and each hole 39′B has a maximum diameter orclearance D_(39′B). Each of the diameters D_(39′A), D_(39′B) may rangefrom 1 to 100 μm, and in this embodiment, the diameter D_(39′B) islarger than the diameter D_(39′A). However, it should be appreciatedthat in other embodiments, the relative sizing of diameters D_(39′A),D_(39′B) may vary greatly while still complying with the principlesdisclosed herein. For example, in some embodiment, the diameter D_(39′A)is larger than the diameter D_(39′B) while in other embodiments, thediameters D_(39′A), D_(39′B) are substantially the same. As previouslydescribed above for screen 38, in some embodiments layers 38′A, 38′B ofscreen 38′ may each comprise a sintered wire mesh or a sintered “DutchTwill” and may further include a lattice structure to withstandoperating pressures within chamber 23. Also, in some embodiments, screen38′ comprises stainless steel, although any suitable material may beused, such as, for example, carbon fiber, a ceramic, a syntheticmaterial, or some combination thereof.

Referring back to FIG. 2, screen 38 (or screen 38′ in some embodiments)is disposed within chamber 23 such that upper end 38 a engages or abutsupper intermediate cap 32A and lower end 38 b engages or abuts lowerintermediate cap 32B. For embodiments that do not includes intermediatecaps 32A, 32B (e.g., assembly 20′ shown in FIG. 3) ends 38 a, 38 b ofscreen 38 may directly engage sealing surfaces 26 a, 28 a of end caps26, 28, respectively. Therefore, when screen 38 is installed withinvessel 22, chamber 23 is divided into a first or inner subchamber 23′and a second or outer subchamber 23″. In some embodiments, screen 38 ismerely placed within chamber 23; however, it should be appreciated thatin other embodiments, screen 38 is secured within chamber 23 duringconstruction of assembly 20. In these embodiments, screen 38 may besecured to the intermediate caps 32A, 32B and/or the caps 26, 28 by anysuitable method, such as, for example bolts, rivets, welding, sintering,or some combination thereof.

Referring still to FIG. 2, in some embodiments, assembly 20 furtherincludes a spiral vortex generator 31 and/or a plurality of vortexgenerating cups 34. Spiral vortex generator 31 comprises a generallyhelically shaped body 33 that includes a first or upper end 33 a and asecond or lower end 33 b opposite the upper end 33 a. Vortex generator31 is disposed within inner subchamber 23′ of chamber 23 such that thelower end 33 b is seated on funnel section 36 of lower intermediate cap32B and generator 31 is substantially coaxially aligned with axis 25.Vortex generating cups 34 are funnel-like structures that are disposedalong the radially inner surface 38 c of screen 38. In particular,referring briefly to FIG. 6, each cup 34 includes a coupling section 35and a baffle 37. Coupling section 35 comprises a cylindrical band whilebaffle 37 extends from section 35 and includes a frustoconical outersurface 37 a and a frustoconical inner surface 37 b. In someembodiments, section 35 and baffle 37 are monolithically formed;however, it should be appreciated that in other embodiments, section 35and baffle 37 are not monolithically formed. As is best shown in FIG. 2,cups 34 are disposed within inner subchamber 23′ such that both sections35 and baffles 37 are coaxially aligned with axis 25 and couplingsection 35 is secured to the radially inner surface 38 c of screen 38.Any suitable coupling or securing method may be employed to mountcoupling section 35 to surface 38 c such as, for example, welding,sintering, bolts, rivets, an adhesive, or some combination thereof whilestill complying with the principles disclosed herein. As will bedescribed in more detail below, during operation of system 10 each ofthe cups 34 and the generator 31 generate flow patterns within fluidsbeing routed from the inner subchamber 23′, through screen 38 and intoouter subchamber 23″ in order to promote substantially even distributionof particulates along surface 38 c of screen 38 to enhance theperformance of system 10. However, it should be appreciated that inother embodiments, the vortex generator 31 and/or the vortex generatorcups 34 are not included in assembly 20 while still complying with theprinciples disclosed herein.

Referring briefly to FIG. 7, wherein another alternative embodiment offilter assembly 20″ is shown. Filter assembly 20″ includes many similarcomponents relative to the filter assembly 20. As a result, likereference numerals are used for like components and features, and sharedcomponents may not be called out or discussed in detail with referenceto FIG. 7, but the same description with regard to FIG. 2 appliesequally to the assembly 20″ of FIG. 7 unless otherwise noted. Instead,the focus of the discussion will be on variations or differences in thefilter assembly 20″ over the filter system 20. For example, in thisembodiment, upper end 38 a of screen 38 abuts or engages outerfrustoconical surface 36 a of intermediate cap 32A and lower end 38 b ofscreen 38 abuts or engages outer frustoconical surface 36 a ofintermediate cap 32B. Additionally, assembly 20″ further includes aplate member 21 axially disposed between upper end 24 a of body 24 andcoupling portion 34 of intermediate cap 32A. Plate member 21 includes aaxially oriented aperture or hole 21 a configured to receive funnelportion 36 of upper intermediate cap 32A. In this embodiment, a maindischarge fluid outlet 27″ is defined between the funnel portion 36 ofintermediate cap 32A and the plate member 21. Specifically, duringoperation, fluid flows through the space between the aperture 21 a andportion 36 of upper intermediate cap 32A and then through outlet 27″into line 16. As a result, assembly 20″ does not include dischargeoutlet 27, previously described for assembly 20. Thus, through placementof the discharge outlet 27′ in the manner shown in FIG. 6, the surface38 c of screen is more fully utilized and thus may offer an enhancedability to both control the disposition of particulates on inner surface32 c and induce cavitation within the fluid during operation. In someembodiments, the plate member 21, upper intermediate cap 32A, and uppercap 26 are all monolithically formed; however, it should be appreciatedthat in other embodiments, member 21, intermediate cap 32A, and cap 26are not monolithically formed while still complying with the principlesdisclosed herein. In addition, in some embodiments of assembly 20″, nointermediate caps 32A, 32B are included (e.g., such as is the case forassembly 20′ shown in FIG. 3) while still complying with the principlesdisclosed herein.

Referring back to FIG. 1, dirty tank 40 and clean tank 60 each compriseany suitable vessel or container capable of holding a volume of fluid(e.g., liquid and/or gas). In some embodiments, tanks 40, 60 maycomprise a metal material; however, it should be appreciated that anysuitable material (e.g., stainless steel, brass) may be used toconstruct tanks 40, 60 while still complying with the principlesdisclosed herein. Additionally, in other embodiments, tanks 40, 60 andmay be disposed within a single container (not shown) such that eachtank 40, 60 comprises a subchamber or section of the single container.

Referring still to FIG. 1, pumps 50 and 70 may comprise any suitabledevice for inducing flow for a fluid. For example, pumps 50, 70 maycomprise any type of centrifugal or positive displacement style pumpwhile still complying with the principles disclosed herein. In thisembodiment, pumps 50 and 70 are each centrifugal pumps that include animpeller (not shown). Further, in this embodiment, each of the pumps 50,70 is coupled to a motor 54, 74, respectively, that is configured torotate the impeller of each respective pump 50, 70, via a shaft, toinduce a flow of fluid therethrough. As the rotational speed of theshaft of each motor 54, 74 increases, the discharge pressure of thepumps 50, 70, respectively, also generally increases. Similarly, as therotational speed of the shaft of each motor 54, 74 decreases, thedischarge pressure of the pumps 50, 70, respectively, also generallydecreases. Motors 54, 74 may comprise any suitable type of motor oractuator while still complying with the principles disclosed herein. Forexample, in some embodiments motors 54, 74 may comprise electric motors,hydraulic motors, internal combustion engines, or some combinationthereof. In this embodiment, motors 54, 74 are electric motors that areconfigured to rotate their respective output shafts in response to anelectrical input signal.

Referring still to FIG. 1, control system 80 generally comprises acentral controller 82 that is electrically linked to various componentswithin system 10 through a plurality of electrical conductors 90. Insome embodiments, conductors 90 comprise electrical cables that arephysically coupled to the controller 82 and the various componentswithin system 10; however, it should be appreciated that in otherembodiments, controller 82 is linked to the various components through awireless connection (e.g., Wi-Fi, BLUETOOTH®, acoustic). Further, inthis embodiment controller 82 includes programmable control logic, suchas, for example, a proportional, integrator, derivative (PID) feedbackcontrol loop which, as will be described in more detail below, adjustscertain system parameters based on feedback obtained from measurementstaken at various points throughout the system 10 in order to optimizecleaning operations.

Control system 80 also includes a plurality of sensors that are disposedwithin and between the various components of system 10 to measurevarious system parameters during operation thereof. In some embodiments,each of the sensors is configured to both sense a given parameter andtransmit (e.g., through one of the conductors 90) data containing themeasured value for processing. In this embodiment, a pressure sensor 81is disposed along feed line 12 between pump 50 and assembly 20, anacoustic sensor 83 is coupled to vessel 22 of assembly, a pressuresensor 85 is disposed along flush line 14, a conductivity sensor 87 anda pressure sensor 89 are disposed along discharge line 16, and apressure sensor 84 is disposed along return line 18. Additionally, inthis embodiment, a flow rate sensor 91 is shown disposed along flushline 14; however, it should be appreciated that in other embodiments,multiple flow rate sensors (e.g., sensor 91) may be disposed throughoutthe system 10 to measure the flow rate of fluids flowing therethroughduring operation. Additionally, in other embodiments, the sensor 83 maycomprise a pressure, flow rate, or other sensor while still complyingwith the principles disclosed herein. As is shown in FIG. 1, each of thesensors 81, 83, 84, 85, 87, 89, 91 are all electrically coupled tocontroller 82 through conductors 90 previously described. Further,pressure sensors 81, 84, 85, 91 may comprise any suitable sensor formeasuring the pressure of a fluid. For example, in some embodiments,pressure sensors 81, 84, 85, and 89 comprise ultrasonic sensors. Also,in some embodiments, pressure sensors are disposed in other portions ofthe filter system 10, such as within the assembly 20.

System 80 further includes a pair of variable frequency drives (VFD(s))86, 88 that are electrically coupled to controller 82 through conductors90. In particular, a first VFD 86 is electrically coupled to motor 54,while a second VFD 88 is electrically coupled to motor 74. Each of theVFDs 86, 88 is configured to control the rotational speed of the motors54, 74, respectively, by altering the electrical signal being routed tothe motors 54, 74, respectively. Because the discharge pressure of thepumps 50, 70 is generally related to the rotational speed of the pumps54, 74, respectively, as previously described, the VFDs 86, 88 are thusconfigured to alter the discharge pressure of pumps 50, 70,respectively, during operation of system 10. The VFDs 86, 88 provide afine level of control for the rotational speeds of the motors 54, 74 andthus the discharge pressures of the pumps 50, 70.

Still further, as is shown in FIG. 1, in this embodiment controller 82is also electrically coupled (e.g., through conductors 90) to each ofthe actuatable valves 43, 44, 45, 47, 48, previously described. Becauseof this connection, controller 82 is configured to actuate each of thevalves 43, 44, 45, 47, and 48 to adjust and control the flow of fluidthroughout system 10 during operation.

Referring now to FIG. 8, the system 10 is generally operable in afiltering state. In particular, in some embodiments system 10 isoperable in an internal control effect mode (ICE™), in which tank 40receives dirty fluid 3 (e.g., used flowback frac water, salt water) froma source (not shown) (e.g., an oil and gas well). The fluid 3 withintank 40 includes several impurities including, among other things,suspended solids and other dissolved impurities. For example, in someembodiments, impurities disposed within fluid 3 include long chainhydrocarbons, benzene, toluene, ethylbenzene, calcium, metals, chlorides(e.g., sodium chloride), or some combination thereof. From tank 40,fluid 3 is pumped, via feed pump 50, from tank 40, through line 12 andcheck valve 42, and into assembly 20. Referring briefly again to FIGS. 2and 4, fluid 3 enters subchamber 23′ of chamber 23 through inlet 11 andflows through holes 39 in screen 38 (or apertures 39′A, 39′B in screen38′ shown in FIG. 5) toward chamber 23″. Any suspended solids which arelarger than the maximum diameter D₃₉ of holes 39 are deposited on theradially inner surface 38 c of screen 38, thus filtering such matter outof the dirty fluid 3. In addition, due to the velocity of the fluid aswell as other factors such as, for example, the geometry of the chamber23, the geometry of the intermediate caps 32A, 32B (for embodimentsemploying intermediate caps 32A, 32B), and the vortex generators 31, 34(for embodiments employing generators 31, 34) flow patterns are createdin fluid 3 within subchamber 23′ to promote a relatively even coating ofsuspended solids on the radially inner surface 38 c of screen 38.

Referring still to FIG. 8, after passing through screen 38 and intoouter subchamber 23″, the newly cleaned fluid 5 then flows out ofsubchamber 23″ through outlet 27 (or outlet 27″ for embodimentsemploying assembly 20″ shown in FIG. 7). As previously described, line16 is fluidly coupled to outlet 27 and thus provides a fluid flow pathfor clean fluids 5 from assembly 20 to tank 60. During this process,valve 43 is actuated to the open position by controller 82 to allowfluids to freely flow between assembly 20 and tank 60. From tank 60, thecleaned fluid 5 may be discharged from the system 10 and/or pumped backto the original source for further use. In addition, in this embodiment,at least a portion of the fluid in tank 60 is directed through returnline 18 by pump 70. Further, some of the fluid discharged by reversingpump 70 flows into recirculation line 17 and back into tank 60 to ensurea sufficient level of fluid within tank 60 during operation. In someembodiments, the flow of fluid through recirculation line 17 establishesa reduction bypass flow path, the size of which varies depending uponthe pressure within the system and the disposition of solids along thesurface 38 c of screen 38. For example, in some embodiments, the flow offluid through the recirculation line 17 establishes about a 50%reduction bypass flow path (when compared with the feed flow rate intoassembly 20); however, in other embodiments, the size of the bypass flowpath may be more or less than 50% while still complying with theprinciples disclosed herein.

In addition, as is shown in FIG. 8, the valve 45 is open. However, inthese embodiments, the pressure within subchamber 23″ is typicallyhigher than the pressure in line 18. As a result fluid communicationbetween subchamber 23″ and the line 18 is at least significantlyrestricted by the check valve 46. However, when the pressure insubchamber 23″ is less than the pressure in line 18, some fluid isallowed to flow past check valve 46 through injection lines 19 and intosubchamber 23″. This small amount of flow into the subchamber 23″ fromthe lines 19 ensures fluid circulation in the subchamber 23″ therebyreducing the likelihood of particulate matter from becoming completelylodged within screen 38. Therefore, in ICE™ mode, use of components suchas, for example, VFD 88 and pump 70 allows for a reduction in the amountof particulate disposition on screen 38 while also simultaneouslyproducing filtered fluid 5 to tank 60 and fine tuning the pressurewithin subchamber 23″ to optimize cavitation (discussed below) withinfilter assembly 20.

Referring now to FIG. 9, system 10 may also be operated in a separationclean mode (SC™) in which the valve 45 is closed, and fluid 3 is pumpedthrough assembly 20 and into tank 60 as previously described above forthe ICE™ mode of operation. However, because the valve 45 is closed, noor substantially no fluid is allowed to return to subchamber 23″, thusreducing the amount or level of fluid circulation in the outersubchamber 23″ through lines 19. In some embodiments, the decision tooperate system 10 in either ICE™ mode or SC™ mode is determined by anumber of factors such as, for example, the specific fluid 3 orimpurities contained within fluid 3, the amount of impurities containedwithin fluid 3, and the specific gravity of fluid 3.

Referring now to FIG. 10, regardless of the chosen operating mode (e.g.,ICE™, SC™, or other mode) over time, particulate matter begins to buildup along the radially inner surface 38 c of screen 38 (see FIG. 2), suchthat it becomes necessary for system 10 to enter a reject state in whichfluid flow is reversed within assembly 20 to sweep or clean at least aportion of this buildup from screen 38. In particular, the controller 82closes valves 43 and 48 and opens the valves 44 and 45. Once the valve48 is closed, the pressure within line 18 increases (e.g., due to theinfluence of pump 70) such that it is greater than the pressure withinsubchamber 23″, thereby allowing fluid to flow from line 18, throughcheck valve 46, into the injection lines 19, and into the inlets 29,previously described. After fluid enters outer subchamber 23″ frominlets 29, it flows through the holes 39 in screen 38 from the radiallyouter surface 38 d to the radially inner surface 38 c and into the innersubchamber 23′ thereby dislodging or sweeping any suspended solids thathave built up along surface 38 c. As shown in FIG. 10, multiple lines 19and inlets 29 are provided to allow the fluid flowing into thesubchamber 23″ to enter at multiple points, and thereby promote cleaningor sweeping of most if not the entire surface 38 c of screen 38. Oncefluid has entered the inner subchamber 23′ from lines 19, it is blockedor restricted from flowing back through line 12 into tank 40 by checkvalve 42. However, because the valve 44 is open, the fluid and the sweptparticulate matter is allowed to flow from inner chamber 23′ throughfluid outlet 13 and into flush line 14. In this embodiment, flush line14 directs the fluid from assembly 20 back to dirty tank 40; however, itshould be appreciated that in other embodiments, line 14 may direct thefluid to another separate tank (other than tank 40 or tank 60) or mayexpel the fluid from the system 10 entirely. In addition, it should beappreciated that in some embodiments, operation in ICE™ mode, previouslydescribed, may allow an operator to minimize the amount of time thesystem 10 must be run in a reject state (e.g., as shown in FIG. 10) dueto the small amount of recirculation back into the chamber 23″ throughlines 19, thereby increasing the amount of time that system 10 may berun to continuously filter fluids (e.g., fluid 3) during operation.

Referring now to FIGS. 8-10, during operation of system 10, controlsystem 80 takes in measurements from the various sensors (e.g., sensors81, 83, 84, 87, 89) and adjusts the speeds of the pumps 50, 70 throughthe VFDs 86, 88, respectively, and actuates the valves 43, 44, 45, 47,48 to enhance and optimize the cleaning of impurities from the dirtyfluid 3. As previously described, in this embodiment, controller 82comprises a PID control loop. In general, the controller 82 receives themeasured values of pressure both from the inner subchamber 23′ via thesensor 81 and from the outer subchamber 23″ via the sensor 89 duringoperation. The controller 82 then adjusts the rotational speed of motor54 and pump 50 through VFD 86, in the manner previously described, toadjust the discharge pressure from pump 50 and thus the pressure withinthe inner chamber 23′ relative to the pressure within outer chamber 23″.In some embodiments, the controller 82 adjusts the rotational speed andthus the discharge pressure of pump 70 either in addition to or in lieuof adjusting the discharge pressure of the pump 50 to further optimizeand control the pressure difference between the subchambers 23′, 23″.Because of the fine level of control provided by the VFDs 86, 88, thedischarge pressures of the pumps 50, 70 can be controlled quickly,continuously, and at various rates of change.

Generally speaking, the goal of these adjustments by controller 82 is tomaintain a predetermined pressure differential or pressure ratio betweenthe subchambers 23′, 23″ to induce and maintain cavitation within thefluid 3 and further precipitate out dissolved solids from fluid 3 inaddition to filtering suspended solids during operation. For example, aspreviously described, during normal operation of system 10 (whether inICE™, SC™, or some other mode of operation), dirty fluid 3 is pumped orflowed from the inner subchamber 23′ to the outer subchamber 23″ suchthat screen 38 may clean or strain suspended solids therefrom. As isbest shown in FIG. 10, during this process suspended solids within theworking fluid 3 collect or accumulate as deposits 15 along the radiallyinner surface 38 c of screen 38 and thus partially clog the holes 39,thereby reducing the effective maximum diameter or clearance D₃₉ andcreating “micro-apertures” or “micro-holes” 39 _(μ). Without beinglimited by this or any particular theory, as fluid flows through thenewly formed micro-holes 39 _(μ), the pressure drops at the throat ofconstriction thereby allowing the static pressure of fluid 3 to fallbelow the vapor pressure, and thus causing cavitation to occur. Ascavitation occurs within the holes 39 _(μ), the solubility of the fluidis altered and dissolved solids (e.g., sodium chloride, NaCl) within thefluid begin to crystalize. In particular, as fluid cavitation occurs,small bubbles form which then subsequently collapse thereby releasing anamount of kinetic energy. The released energy operates to dissociatepolar water molecules from surrounding cations and anions, which werepreviously bonded to the water molecules in the aqueous solution. Thenewly released cations and anions then recombine and thus precipitateout of solution in the form of crystals. These newly formed crystalsadhere to the nucleation sites formed by deposits 15 distributed alongthe radially inner surface 38 c and thus are also filtered out of thefluid 3. In order for cavitation to occur in the manner described above,the effective diameter D₃₉ of the micro-holes 39 _(μ) must fall within acertain range. In at least some embodiments, the pressure differentialbetween the subchambers 23′, 23″ is directly related to the size of themicro-holes 39 _(μ). Thus, at least one goal of the control system 80 isto optimize the pressure differential or pressure ratio betweensubchamber 23′, 23″ such that micro-holes 39 _(μ) form along theradially inner surface 38 c of screen 38 thereby allowing cavitation tooccur within and proximate the holes 39 _(μ) to enhance the assembly20's (or the assemblies 20′, 20″) ability to remove dissolved impuritiesfrom the fluid in addition to suspended solids. In some embodiments, thedesired pressure differential is achieved and maintained throughobservation of the pressures measured in both the subchamber 23′ (e.g.,through sensor 81) and the subchamber 23″ (e.g., through sensor 89), andsubsequent adjustment of the rotational speed and thus the dischargepressure of the pump 50 and/or the pump 70 (e.g., via VFDs 86, 88,respectively).

In one specific example, when the measured pressure differential betweenthe subchambers 23′, 23″ rises over a pre-determined value or range ofvalues, the controller 82 directs the VFD 86 to decrease the rotationalspeed and thus the discharge pressure of the feed pump 50. Conversely,when the measured differential pressure between the subchambers 23′, 23″falls below the pre-determined value of range of values, the controller82 directs the VFD 86 to increase the rotational speed and thus thedischarge pressure of the feed pump 50. The pre-determined value orrange of values for the desired pressure differential is determined by anumber of factors, including, for example, the type of fluid 3, thelevel or amount of impurities contained within fluid 3, or the specificgravity of fluid 3. The fine level of control provided by the VFD 86allows flexibility in the way the feed pump 50 reacts to the measuredpressure differential. The VFD 86 can cause the feed pump 50 to respondquickly to pressure changes, and to vary the pressure response based onthe rate of change of the measured pressure differential.

Referring still to FIGS. 8-11, in some embodiments, controller 82 mayadjust the discharge pressure of the feed pump 50 and/or the pump 70based at least partially on the measurements obtained from theconductivity sensor 87 disposed on line 16. Such adjustment may takeplace either in addition to or in lieu of adjustments based on othermeasured values (e.g., pressure). In particular, for some applications,many of the dissolved impurities within the fluid comprise ions or ioniccompounds (e.g., sodium chloride). Thus, during operation sensor 87measures electrical properties (e.g., electrical conductivity) of thefluid 5 in discharge line 16 in order to detect the level of dissolvedimpurities within the fluid 5 to give an indication of the effectivenessof the cleaning process taking place within assembly 20 (e.g., bycomparing the sensed conductivity to a known or predetermined value orrange of values). The controller 82 may then adjust the dischargepressure of the pump 50 and/or the pump 70 (e.g., via the VFDs 86, 88,respectively) based at least partially on the output from the sensor 87to optimize the pressure differential between the subchambers 23′, 23″and thus facilitate fluid cavitation to remove such dissolvedimpurities.

Further, in some embodiments, controller 82 may adjust the dischargepressure of the pump 50 and/or the pump 70 based at least partially onthe measurements obtained from the acoustic sensor 83 disposed on vessel22. Such adjustment may take place either in addition to or in lieu ofadjustments based on other measured values (e.g., pressure,conductivity). In particular, when cavitation is occurring withinchamber 23 small bubbles form and collapse in the manner previouslydescribed, thereby resulting in the formation of a pressure wave. Thesegenerated pressure waves have a determinable acoustic frequency ω_(R).Thus, in at least some embodiments, the controller 82 is configured tomeasure an audio signal in the frequency range for fluid in subchamber23″ via the sensor 83 during operation and compare it to apre-determined value or range of values. The pre-determined value orrange of values for the frequency is determined based on the expectedacoustic resonant frequencies ω_(R) which result when the fluidcavitation is occurring. In some embodiments, the anticipated frequencyof vibration ω_(R) in which cavitation is occurring within chamber 23may be between 200 Hz and 20,000 Hz. The controller 82 may then adjustthe discharge pressure of the pump 50 and/or the pump 70 (e.g., via theVFDs 86, 88, respectively) based at least partially on the output of thesensor 83 to optimize the pressure differential between the subchambers23′, 23″ and thus maintain fluid cavitation to remove any dissolvedimpurities. As previously discussed, the discharge pressure response ofthe pumps 50, 70 is immediate, variable, and continuous as needed basedon the functionality of the VFDs 86, 88.

Referring to FIGS. 12-13, another embodiment of a filter system 100 isshown. Filter system 100 includes many similar components relative tothe filter system 10. As a result, like reference numerals are used forlike components and features, and shared components may not be calledout or discussed in detail with reference to FIGS. 12-113 but the samedescription with regard to FIGS. 1-11 applies equally to the system ofFIGS. 12-13 unless otherwise noted. Instead, the focus of the discussionwill be on variations or differences in the filter system 100 over thefilter system 10. In general, the system 100 is the same as system 10,previously described; however, system 100 does not include arecirculation line 17. Instead, the filter system 100 includes anadditional prime tank 165 that is coupled to discharge line 16 through abranch 117. Prime tank 165 is also coupled to pump 70 through a primingline 118. Line 118 is further coupled to the pair of injection lines 19,previously described. Further, as shown in FIG. 12, the valves 46 and 45are also disposed along line 118. Referring specifically to FIG. 13, theoperation of system 100 is substantially the same as described above forsystem 10; however, when system 100 enters a reject state of operation,fluid 5 flows from prime tank 165 (instead of clean water tank 60),through line 118, and into lines 119 to clean or sweep the screen 38.

Referring now to FIG. 14 wherein a method 200 for filtering a fluidcontaining some amount of dissolved impurities (e.g., fluid 3) is shown.In order to provide context and enhance clarity, method 200 will beexplained with reference to components and features of filter system 10,previously described; however, it should be appreciated that method 200may be carried out with any suitable system other than system 10 (e.g.,system 100 or some other suitable system) while still complying with theprinciples disclosed herein.

Method 200 begins by flowing dirty fluid (e.g., fluid 3) through afilter member in step 205. The filter member may be any suitable screen(e.g., screen 38, 38′, etc.) membrane or other suitable member forfiltering impurities from a fluid while still complying with theprinciples disclosed herein. As fluid is being routed through the filtermember in step 205, fluid cavitation is induced in step 210 such thatbubbles are formed and then subsequently collapse in the mannerdescribed above. As a result of the cavitation occurring in step 210, atleast a portion of the dissolved impurities within the dirty fluid areprecipitated out of the dirty fluid in step 215. In some embodiments,dissolved solids are precipitated out of the dirty fluid in step 215 inthe same manner as previously described above for system 10. The method200 next includes capturing the impurities precipitated out of the dirtyfluid in step 215 with the filter member in step 220. Finally, themethod 200 includes controlling the pressures (e.g., through pumps 50,70, motors 54, 74, and VFDs 86, 88) on either side of the filter member(e.g., in subchambers 23′, 23″) in step 225 to facilitate and maintainthe fluid cavitation occurring in step 210.

In some embodiments, the dirty fluid is salt water (e.g., such as seawater) and the dissolved impurities comprise, among other things, sodiumchloride (NaCl). Thus, in these embodiments, when cavitation occurs instep 205, the kinetic energy released as a result of the collapse ofbubbles formed during cavitation precipitates the sodium (Na) andchloride (CI) molecules out of the solution in the manner previouslydescribed above such that crystalized sodium chloride NaCl forms whichis then captured with the filter member in step 220.

Referring now to FIG. 15 wherein another method 300 for filtering afluid containing some amount of dissolved impurities (e.g., fluid 3) isshown. In order to provide context and enhance clarity, method 300 willbe explained with reference to components and features of filter system10, previously described; however, it should be appreciated that method300 may be carried out with any suitable system other than system 10(e.g., system 100 or some other suitable system) while still complyingwith the principles disclosed herein.

Method 300 begins by flowing a fluid from a first side (e.g., subchamber23′) of a filter member to a second side (e.g., subchamber 23″) of thefilter member in step 305. As with method 200, previously described, thefilter member may be any suitable screen (e.g., screen 38, 38′, etc.)membrane or other suitable member for filtering impurities from a fluidwhile still complying with the principles disclosed herein. In addition,in some embodiments, the fluid contains suspended and/or dissolvedimpurities (e.g., NaCl). The method 300 also includes inducing fluidcavitation within the fluid to precipitate out at least a portion of thedissolved impurities in step 310. In some embodiments, dissolved solidsare precipitated out of the fluid in step 310 in the same manner aspreviously described above for system 10. The method 300 furtherincludes controlling a pressure differential across the filter member(e.g., through pumps 50, 70, motors 54, 74, and VFDs 86, 88), betweenthe first and second sides (e.g., in subchambers 23′. 23″) in step 315,and maintaining or further inducing the fluid cavitation within thefluid in step 320 in response to the controlling of step 315.Thereafter, in some embodiments, method 300 reinitiates step 305.

Method 300 also includes several optional steps of which all or some maybe performed in addition to steps 305-320, previously described. Inparticular, in some embodiments, method 300 includes the optional stepof sensing a pressure on the first side (e.g., subchamber 23′) of thefilter member in step 325 and sensing a pressure on the second side(e.g., subchamber 23″) of the filter member in step 330. Thereafter,step 335 includes computing a pressure differential between the sensedpressures in steps 325, 330. Finally, method 300 includes comparing thecomputed pressure differential of step 335 to a predetermined value orrange of values in step 340 (e.g., with controller 82) such that thecomparison may be used to at least partially affect the controlling ofstep 315.

In some embodiments, method 300 also includes the optional step ofsensing a frequency of pressure waves on the second side (e.g.,subchamber 23″) of the filter member (e.g., with sensor 83) in step 345.Thereafter, step 350 includes comparing the sensed frequency in step 345to a predetermined value or range of values such that the comparison maybe used to at least partially affect the controlling of step 315 (e.g.,with controller 82).

In still some embodiments, method 300 includes the optional step ofsensing the conductivity of the fluid on the second side of the filtermember (e.g., with conductivity sensor 87) in step 355. Thereafter, step360 includes comparing the sensed conductivity in step 355 with apredetermined value or range of values such that the comparison may beused to at least partially affect the controlling in step 315 (e.g.,with controller 82).

Through use of a filter system (e.g., system 10, 100) according to theprinciples disclosed herein, the filtration of fluid (e.g., usedflowback frac water, salt water) is enhanced, thereby facilitating moreeffective removal of both suspended solids and other dissolvedimpurities. Further, through use of a filter system according to theprinciples disclosed herein, more effective filtration of a fluid isachieved by inducing and maintaining cavitation in the filtered fluidduring the filtering process by a control system (e.g., system 80) thatclosely manages and manipulates differential pressures in the system.

While embodiments disclosed herein have shown only a single filterassembly 20 (or assembly 20′) included within system 10 (or system 100),it should be appreciated that in other embodiments, more than oneassembly 20 (or assembly 20′) may be included either in parallel, inseries, or in some combination thereof within system 10 or 100 whilestill complying with the principles disclosed herein. In addition, whileembodiments disclosed herein have included two lines 19, it should beappreciated that other embodiments may have more or less than two lines19. Further, while embodiments disclosed herein have described thecontroller 82 as being a single component, it should be appreciated thatin other embodiments, the controller 82 may comprise multiplescomponents and may comprise multiple individual control units or controlcircuits which correspond to different components and features of thefilter system (e.g., system 10, 100). Still further, while embodimentsdisclosed herein have described the use of pressure, flow rate,acoustic, and conductivity sensors within the systems 10, 100, it shouldbe appreciated that in other embodiments, other sensors may be utilizedwith the system 10, 100 which measure various other values andparameters while still complying with the principles disclosed herein.For example, in some embodiments, temperature sensors may be disposedalong the various lines 12, 14, 16, 17, 18, 117. Additionally, in someembodiments level sensors may be included on the tanks 40, 60, 165 toprovide a measure of the level of fluids within tanks 40, 60, 165 duringoperation. Further, while embodiments disclosed herein have shown anddescribed only a single system 10, 100, it should be appreciated that insome embodiments, multiple systems 10 or 100 may be coupled in series,in parallel, or in some combination thereof in order to effect cleaningof fluids during operation. Still further, while embodiments disclosedherein have described a filter system (e.g., system 10, 100) being usedto filter particles from fluid used in the oil and gas industry duringdrilling or completion of earthen wellbores, it should be appreciatedthat in other embodiments, the previously described filtering systemsmay be used in connection with any suitable processes or industry whichrequires the filtration of particles from fluids. For example, someembodiments of filter systems 10 and/or 100, previously described, maybe used to filter fluids such as industrial waste waters, reclaimedwaters from food processing, and sea water while still complying withthe principles disclosed herein. While only the filter assembly 20′shown in FIG. 3 has been shown and described to include a mountingdevice (e.g., plate 73) it should be appreciated that any embodiment ofassemblies 20 and 20″ may also include plate 73 or some other suitablemounting device while still complying with the principle disclosedherein. Further, it should be appreciated that in some embodiments, VFDs86, 88, may be replaced with any suitable throttling or adjustmentassembly configured to adjust the output rotational speed of the motors54, 74 to control the pressure differential between the subchambers 23′,23″ while still complying with the principles disclosed herein. Forexample, in some embodiments, motors 54, 74 are hydraulically driven andVFDs 86, 88 are replaced with throttling valves which control the flowof hydraulic fluid through motors 54, 74 thus controlling the outputrotational speed thereof.

While preferred embodiments have been shown and described, modificationsthereof can be made by one skilled in the art without departing from thescope or teachings herein. The embodiments described herein areexemplary only and are not limiting. Many variations and modificationsof the systems, apparatus, and processes described herein are possibleand are within the scope of the invention. For example, the relativedimensions of various parts, the materials from which the various partsare made, and other parameters can be varied. Accordingly, the scope ofprotection is not limited to the embodiments described herein, but isonly limited by the claims that follow, the scope of which shall includeall equivalents of the subject matter of the claims. Unless expresslystated otherwise, the steps in a method claim may be performed in anyorder. The recitation of identifiers such as (a), (b), (c) or (1), (2),(3) before steps in a method claim are not intended to and do notspecify a particular order to the steps, but rather are used to simplifysubsequent reference to such steps.

What is claimed is:
 1. A method of filtering a fluid, comprising:flowing a fluid from a first side of a filter member, through holes inthe filter member, and to a second side of the filter member, the fluidcontaining suspended solids and dissolved impurities; accumulating atleast a portion of the suspended solids in the holes of the filtermember to constrict the holes into micro-holes, thereby causing apressure differential across the micro-holes and inducing fluidcavitation in the fluid in the micro-holes that precipitates out atleast a portion of the dissolved impurities; accumulating at least aportion of the precipitated impurities in the micro-holes of the filtermember to filter the precipitated impurities from the fluid; andcontrolling an effective diameter of the micro-holes by continuouslycontrolling the pressure differential across micro-holes to maintain thefluid cavitation in the fluid in the micro-holes and the filtering ofthe precipitated impurities.
 2. The method of claim 1, wherein flowingthe fluid comprises pumping the fluid with a feed pump; whereincontrolling the pressure differential comprises adjusting an outputpressure of the feed pump.
 3. The method of claim 2, further comprising:sensing a pressure on the first side of the filter member; sensing apressure on the second side of the filter member; and adjusting theoutput pressure of the feed pump based on the pressures.
 4. The methodof claim 2, further comprising: sensing a frequency of pressure waves onthe second side of the filter member; and adjusting the output pressureof the feed pump based on the frequency.
 5. The method of claim 2,further comprising: sensing the conductivity of the fluid on the secondside of the filter member; and adjusting the output pressure of the feedpump based on the conductivity.
 6. A method of filtering a fluid,comprising: flowing a fluid from a first side of a filter member,through a plurality of apertures in the filter member, and to a secondside of the filter member, the fluid containing suspended solids anddissolved impurities, accumulating at least a portion of the suspendedsolids on the filter member thereby causing a pressure differentialacross the filter member and inducing fluid cavitation in the fluid thatprecipitates out at least a portion of the dissolved impurities;accumulating at least a portion of the precipitated impurities on thefilter member to filter the precipitated impurities from the fluid; andcontrolling the pressure differential to a desired pressure differentialto maintain the fluid cavitation and filtering of the precipitatedimpurities; wherein the controlling the pressure differential to thedesired pressure differential is based on a pre-determined range of aneffective diameter of the apertures.
 7. The method of claim 1 whereinthe flowing the fluid step is in an initial filtering and feed flowdirection, and each step of the method occurs in the same feed flowdirection.